Over tightening a drain plug will not damage the o-ring. The o-ring fits in a groove that is dimensioned such that the o-ring will compress to the proper fit regardless of the torque applied to the drain plug (assuming the plug is tightened enough to be fully seated).

Drain plug o-rings should last almost forever. I'd be looking for a burr or some other anomaly with the o-ring groove or the mating sealing surface if I found a cut, nick or tear in any o-ring.

 

Changed mine several times without replacing o-rings. The ring you "found" may have fit around the plug but was too thick in cross-section, so it didn't fit into the c'bore, flared out and split. H-D is like most OEMs, they get those things custom made to their own specs and maybe sometime you might find one to work, short term.

 

Right, even the correct O ring will pinch out if left dry. It definitely helps to put some clean engine oil on the O ring. Install the plug by hand and gently turn the plug in until you feel it seat...then rotate the plug back and forth slightly to make sure the O ring is seated and not pinching out. Torque to spec and double check the drain plug with an inspection mirror all the way around to make sure the O ring isn't hanging out anywhere. Pinching the O ring is real easy to do. At my 1,000 mile service the dealer left my engine oil drain plug loose with the O ring pinched out and tightened the transmission drain plug and cut the O ring with a piece of it hanging out. Yea both were leaking and the loose engine oil drain plug could have killed me or at least have done some expensive damage. I'm lucky I checked their work...they don't.

I don't know about the later models but my 2000 Dyna's drain plug does not have a very deep O ring retention groove, making for an easy escape for the O ring if you're not careful or paying attention. Pay attention to the details.

Tech23

 

What about thread sealant? Anybody use that? I know you don't want to use Loctite, but something like Plumbers Putty? Would Plumbers Putty stand the heat or breakdown and create an even bigger mess?

I've got a leak that I'm chasing right now. I think it's coming from the hex plug that sits next to the oil drain plug, it's the one that the Service Manual says "Do Not Remove." I looks like a pipe fitting plug. Anyone ever take that one out?

Mike

 

Harley will give me o rings

I find THAT hard to believe.

 

Me too. They used to give them to me for $1 apeice I think it was.

If you have a industrial supply company, or maybe even Motor Parts & Beasring store around, the proper size O ring is a #111. Last batch I bought I think I paid $.17 for them. I prefer Teflon tape on my plugs. 3 wraps in the direction of the threads.

 

[quote=machinistmate;9949733] H-D is like most OEMs, they get those things custom made to their own specs.../quote]

Uh... no. A bike, or anything for that matter, would costs thousands more if every o'ring, washer, bolt etc. was custom made.

Almost every piece of hardware on the bike is standard sizing.

 

The dealers sell an oil change gasket kit. For the Touring bikes anyway. I keep a spare on hand at all times for just such an occassion. +1 on doing the swap quickly and keeping a clean container under the bike so that you can just pour what does come out, right back in.

 

For years I have used plumber PVC putty compound... no leaks... EVER! :-)

 

They gave me o rings for free. This was just after I purchased an oil filter and four quarts of oil, so the term give is relative. The gave me three, which is the number of motorcycles I have bought from them. I guess this makes us even.